Multilevel concrete building of precast modular units

ABSTRACT

A plural story building comprised of a number of basic precast concrete components, said components being held to a minimum and being so constructed to allow factory assembly of the components to such an extent that plumbing, electrical wiring, heating and ventilating, closets, bathroom fixtures, lighting fixtures, door frames, window frames, etc., are installed prior to shipment to the erection site thereby reducing field erection time. The basic components consist mainly of a corridor box forming the inside corridor&#39;&#39;s load bearing walls and ceiling and also resisting horizontal forces, a column component forming the outside walls, a slab component forming the floor for one level and the ceiling of the level below, and wherein the slab component is supported by and attached to a shelf in both the corridor box and the combination column, beam, panel component.

1 MULTILEVEL CONCRETE BUILDING OF PRECAST MODULAR UNITS [75] Inventors:James F. McCaul, III, Birmingham,

, Ala.; Lloyd A. Compton, Denver,

Colo.

[731 Assignee: Schokbeton Products Corp.,

Birmingham, Ala.

[22] Filed: Apr. 26, 1971 [21] Appl. No.: 137,582

52 us. C1 52/236, 52/295, 52/79,

52/262, 52/263, 52/251 [51] Int. Cl E04h 1/00 [58] Field of Search52/79, 234, 236, I 52/289, 295

[56] v References Cited UNITED STATES PATENTS 1,886,962 11/1932 Roche52/79 3,514,910 6/1970 Comm 52/79 2,064,789 12/1936 Faber 52/2363,643,814 2/1972 Martin 52/236 3,566,558 3/1971 Fisher 52/236 3,642,3392/1972 vRuderfer... 52/236 3,568,380 3/1971 Stucky 52/79 3,510,997 5/1970 Ratych 52/79 2,043,697 6/1936 Deichmann'. 52/236 FOREIGN PATENTS ORAPPLICATIONS 7/1969 Great Britain 52/79 639,437 5/1962 ltaly 52/79431,023 8/1967 Switzerland 52/79 6,709,528 1/1968 Netherlands 52/79Primary Examiner-Frank L. Abbott Assistant ExaminerLeslie A. BraunAttorney-James W. Grace 57 ABSTRACT A plural story building comprised ofa number of basic precast concrete components, said components beingheld to a minimum and being so constructed to allow factory assembly ofthe components to such an extent that plumbing, electrical wiring,heating and ventilating, closets, bathroom fixtures, lighting fixtures,door frames, window frames, etc., are installed prior to ship ment tothe erection site thereby reducing field erection time. The basiccomponents consistmainly of a corridor box forming the inside corridorsload bearing walls and ceiling and also resisting horizontal forces, acolumn component forming the outside walls, a slab component forming thefloor'for one level and the ceiling of the level below, and wherein theslab component is supported by and attached to a shelf in both thecorridor box and the combination column, beam, panel component.

4 Claims, 12 Drawing Figures Austria 52/79 PATENTED 2 m3 SHEEI 3 [IF 6PATENTED BET 2|973 SHEET '5 BF 6 MULTILEVEL CONCRETE BUILDING OF PRECASTMODULAR UNITS DESCRIPTION OF PRIOR ART It has always been desirable toprovide a multi-story building that can be erected and occupied in ashort period of time. Plural story buildings have long been comprised ofmany parts varying in complexity of function and difficulty of erection.For example, U. S. Pat. No. 1,886,962 shows six to eight individualunits that must be held in alignment simultaneously in order to insertone bolt through a hole common to each of them. However, our inventionprovides an improved building design of precast structure composed offewer parts than usual and allows factory assembly of items usuallyinstalled after the structure is erected.

SUMMARY OF THE INVENTION It is the primary object of this invention toprovide a multi-story precast concrete building composed of factoryprepared components containing the fixtures and utility items needed byits future inhabitants. It is a further object of this invention tocombine the need for structural strength and'the need for ducts, wireways, pipe chases, etc.

It is yet another object of this invention to provide precast componentsthat will align and attach in such a manner as to maintain the desireddimensional integrity of the building without the usual steps ofaligning.

columns vertically and horizontally prior to making the finalconnections. Thus, the columns are self aligning both horizontally andvertically by nature of their unique construction.

These objects and others are obtained by a plural story builingcomprised of a number of basic precast concrete components, saidcomponents being held to a minimum and being so constructed to allowfactory assembly of the components to such an extent that plumbing,electrical wiring, heating and ventilating, closets, bathroom fixtures,lighting fixtures, door frames, window frames, etc., are installed priorto shipment to the erection site thereby reducing field erection time.The basic components consist mainly of a corridor box forming the insidecorridors load bearing walls and ceiling and also resisting horizontalforces, a column component forming the outside walls, a slab componentforming the floor for one level and the ceiling of the level below, andwherein the slab component is supported by and attached to a shelf inboth the corridor box and the column component.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view inpartial cross section of a complete building according to the subjectinvention.

FIG. 2 is a perspective view in partial cross section of a corridor boxand attached appurtenances.

FIG. 3 is a perspective view ofa corridor box connector.

FIG. 4 is a partial sectional elevation taken along line AA of FIG. 1showing a corridor box connection.

FIG. 5 is a perspective view of a column component.

FIG. 6 is a perspective view in partial cross section of a slab section.

FIG. 7 is a partial elevation of a connection of a slab section to acorridor box and to a column component.

FIG. 8 is a perspective view of a pair of stair sections.

FIG. 9 is a vertical fragmentary sectional view taken along line 99 ofFIG. 8 showing a typical connection of the stair box sections.

FIG. 10 is a perspective view of a bathroom'module.

FIG. 11 is a vertical transverse sectional view taken along lines ll-llof FIG. 10 showing additional details of the bathroom module.

FIG. 12 is a perspective view of a kitchen unit.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to the drawings, thereis shown in FIG. 1 a completed building, indicated generally by numeral1, resting on a foundation 2 of poured concrete or suitable alternative.Building 1 comprises three basic build ing components namely a corridorbox 3, a column section 4, a slab section 5, the particular constructionof which is described more fully below. The stub columns 6 are fixed toa base plate that allows precise alignment both vertically andhorizontally while both stub column and base plate are attached tofoundation 2. Corridor boxes 3 rest on and are attached to thefoundation with anchor bolts allowing precise vertial and horizontalalignment. Column sections 4, uniformly rest on stub columns 6 so as tobe at the same height relative to one another at each story level.

In FIG. 2, there is shown the detailed construction of corridor box 3having open ends, ribbed walls and an open bottom. Box 3 comprisesreinforcing cage 7, door opening 8, door frame 9, electrical box 10,opening for electrical box 1 1, water heater l2, piping l3, and nailerstrip 14. The ribbed walls comprise vertical sidewalls 3a dependingdownwardly from the top wall 3b and having integral vertical ribs 3cextending outwardly in a generally normal direction therefrom, each ofsaid ribs 3c forming a two-tiered step means at its upper junction withsaid vertical depending sidewalls 3a. The two-tiered step meanscomprises lower and upper seats 3d and 3e respectively. Lower seat 3d isinset from the outer face 3f of the rib 30 to an upstanding wall 3g ofsaid rib and the upper seat 3e is inset from the top edge 3h of the wall3g along the horizontal plane of the top of the rib 3:: to a secondupstanding wall formed by the outer wall 3] of the depending verticalsidewall 3a. The particular construction of the reinforcing cage 7, isnot part of our invention. Its construction, amount and size ofreinforcing, etc., will depend on the loading conditions experienced butshould be obvious to one of ordinary skill in the art. Otherappurtenances may be similarly provided. Similarly the particularlocation of door openings, etc., may be changed to suit the conditions.A plurality of connectors 15 are embedded in the corridor boxes at thelower most edges of the wall sections thereof. Details of such aconnector are shown in FIG. 3. A portion 16 of each connector 15protrudes beyond the present structure of the box, but into theenclosure of access opeing 17 in order to receive a corresponding archorbolt 18 embedded in and protruding beyond the upper most surface of anadjoining corridor box. A connection of each vertically adjacent stackedpairs of corridor boxes is made as shown in FIG. 4. The number ofconnectors 15 and 18 provided for each box is a matter of design choiceand is not a part of this invention. The column section as shown in FIG.5, provides two columns 19 and 20, with a beam 21 spanning between andcantilever beams 22 and 23 extending outwardly halfway to the nextcolumn. Also provided by this section are architectural panels 24forming the outside wall while in specific locations leaving openingsfor windows if desired. The placement or selection of panels versuswindows, as well as the type of panel, can be varied at will inaccordance with the intent of the architect. To allow connection of thecolumns of one story to those of the next and to maintain horizontal andvertical alignment there is provided in the top of each column aconnector 25, and in the bottom of each column a recess 26, shown indotted line to receive the connector. A preferred connector is shown anddescribed in copenidng application Ser. No. 137,680, now U. S. Pat. No.3,702,523, issued Nov. 14, 1972 and assigned to the same assignee as thesubject invention. However, alternative means of connection could beprovided such as shown in U. S. Pat. No. 3,110,982. This would, however,present alignment problems which are overcome by the preferred means ofconnection.

In FIG. 6, there is shown a slab section with reinforcing cage 27 and aprestressing strand 28. The amount, size and location of reinforcingrods and/or prestressing strands is a matter of design choice and is nota part of this invention. Ceiling board may be attached to ribs 29 atthe bottom of the slab section in a conventional manner; however, in thepreferred embodiment an embedded nailer strip is used, details of whichare shown and described fully in copening application Ser. No. 138,268,filed Apr. 28, I971 assigned to common assignee. The slab sections 5 areattached on one end to the column sections by means of a connector 30 asshown in FIG. 7 and to the corridor box by means of a connector 31 alsoshown in FIG. 7. The number and size of connectors 30 and 31 are amatter of design choice, however, in the preferred embodiment each slabsection is connected utilizing two connectors 30, one at each outer rib,attached to the column section by means of embedded anchor bolts 32 andto the slab section by means of through bolts 33 extending through coredholes provided in the slab section and also two connectors 31, one ateach outer rib, attached to the corridor box by means of through bolts34 and to the slab section by means of through bolts 35; all throughbolts 34 and 35 extending through cored holes provided in the corridorbox and the slab section. Referring again to FIG. 1, there are providedstair boxes 36 and 37, each having stairs and landings. FIG. 8 shows apair of stair boxes in more detail. The stair boxes ar joined by boltingtogether two embedded connectors 38 as shown in FIG. 9. FIG. shows aprefabricated bathroom in the shape of a rectangular parallelepiped.FIG. 11 shows the inside of the bath unit with lavatory 39, commode 40,exhaust vent 41, and glass shower door 42 all in one piece and needingonly to be connected to the building's service lines. In FIG. 12 thereis provided a prefabricated kitchen with sink 43, garbage disposal 44,hot water heater 45, range 46, refrigerator 47, range hood 48, cabinets49, lights 50, fuse box 51, and junction boxes 52 all in either one ortwo pieces, complete with all service lines and needing only to beconnected to the building's service lines.

Building end walls are comprised of precast, insulated architecturalpanels bolted to structural members in a manner well known to thoseskilled in the art and do not form a part of this invention.

All precast components described above may be cast in accordance withconventional methods as well known to those skilled in the art. Steelforms are preferably employed in our invention because of their longlife characteristics and the need for many such components in any onebuilding. Dimensional integrity is also an important factor. Anyprefabricated reinforcing cages and prestressing strands needed areplaced prior to casting all in accordance with the strength needed andin such a manner as is also well known to those skilled in the art.

METHOD OF INSTALLATION Referring again to the drawings and morespecifically FIG. 1, there will be provided in the foundations anchorbolts to which the stub columns 6 are fixed and precisely aligned.Anchor bolts are also provided in the foundation for the corridor boxes3, stair boxes 36 and 37, and the elevator boxes 53. These componentsare precisely aligned and fixed to the foundations. In the preferredembodiment the utility lines servicing the building emerge from thefoundations and attach to lines 13 that have been provided as part ofthe corridor boxes. Now the column sections 4, for the first story canbe set atop the stub columns. These sections 4 are self-aligning due torecess 26 in the bottom of the column mating with the connector 25provided in the top of the stub column 6 and in the top of the columnsections 4. The slab sections can now be set on the seat 54 provided inthe column section 4 and the seat 32 provided in the corridor boxes.Connectors 30 and 31 shown in FIG. 7, are provided to attach the slabsections to the corridor boxes and column sections. Similar connectionsare made to a seat 56 provided in the elevator boxes 53 or a seat 57provided in the stair boxes. End walls attach to the end corridor boxesor stair boxes and to the column sections. Bathroom sections FIG. 10 areset in their required location, plumbing and electical connections madeand doors hung. Kitchen units FIG. 12 are set in their desired locationand plumbing and electrical connections are made. Additional stories areadded similarly until the desired number are in place. The top slabsection now becomes the roof and is covered with a moisture proofmembrane, insulation and a built-up roofing surface. The elevators areinstalled in the elevator shafts. A precast elevator penthouse isprovided to house the elevator hoisting equipment and electrical switchgear. This allows all equipment to be installed in the penthouse atground level prior to its being set in place atop the elevator shaftneeding only to have the hoisting cables connected and electricalconnections completed. Prefabricated-prefinished partition walls are setin place throughout the building, windows are installed, doors hung andcarpets installed, and other finish work completed, all of which formsno part of the subject invention.

While only a preferred embodiment has been illustrated, otherembodiments will be apparent with units constructed and arrangeddifferently yet within the scope of the invention as defined in theappended claims.

We claim:

1. A multistory building including a plurality of living compartments,

the improvement comprising corridor means, vertical column means andslab means, each of said vertical column means, slab means, and corridormeans being of unitized reinforced precast concrete construction, saidcorridor means and said vertical column means being spaced parallel andopposite one another and said slab means extending between said corridormeans and said vertical column means, said corridor means being ofsubstantially inverted U-shape and including a top wall and two oppositeand substantially parallel, vertical sidewalls depending downwardlytherefrom, each of said sidewalls having a plurality of integralvertical ribs extending outwardly in a generally normal directiontherefrom, each of said ribs forming a twotiered step means at theirupper junction with said depending sidewalls, said two-tiered step meanscomprising upper and lower seats in which said lower seat is inset fromthe outer face of said rib to an upstanding wall of said rib and saidupper seat is inset from the top edge of said upstanding wall of saidrib along the horizontal plane of the top of said rib to a secondupstanding wall formed by the outer wall of said depending side of saidcorridor means, mechanical fastener means at least partially embedded insaid top wall and extending into said recesses for connection tocomplementary fastener means extending outwardly from a corridor means,supported on said upper seats; said slab means resting on said lower oneofsaid seats of said ribs, further mechanical fastening means connectedto said slab means at each end thereof for permanently attaching saidslab means to said vertical column means at one end thereof and to saidcorridor means at the other end thereof, whereby said slab means formsthe ceiling of one of said plurality of living compartments and thefloor of another of said plurality of living compartments of saidmultistory building, and said vertical column means forms one outsidewall of said one of said plurality of living compartments and saidcorridor means forms the opposite wall of said one of said plurality ofliving compartments.

2. A multistory building as in claim 1 wherein said vertical columnmeans comprises a plurality of column sections, each said column sectionbeing of integrally cast one piece construction comprising twosubstantially vertical columns, each said column being substantiallyparallel to and spaced a distance from one another, connection means ateach end of said vertical columns, a beam extending between saidvertical columns and intersecting therewith at substantially therespective midpoints thereof, and said beam including means forsupporting and securing said slab means.

1. A multistory building including a plurality of living compartments,the improvement comprising corridor means, vertical column means andslab means, each of said vertical column means, slab means, and corridormeans being of unitized reinforced precast concrete construction, saidcorridor means and said vertical column means being spaced parallel andopposite one another and said slab means extending between said corridormeans and said vertical column means, said corridor means being ofsubstantially inverted U-shape and including a top wall and two oppositeand substantially parallel, vertical sidewalls depending downwardlytherefrom, each of said sidewalls having a plurality of integralvertical ribs extending outwardly in a generally normal directiontherefrom, each of said ribs forming a two-tiered step means at theirupper junction with said depending sidewallS, said two-tiered step meanscomprising upper and lower seats in which said lower seat is inset fromthe outer face of said rib to an upstanding wall of said rib and saidupper seat is inset from the top edge of said upstanding wall of saidrib along the horizontal plane of the top of said rib to a secondupstanding wall formed by the outer wall of said depending side of saidcorridor means, mechanical fastener means at least partially embedded insaid top wall and extending into said recesses for connection tocomplementary fastener means extending outwardly from a corridor means,supported on said upper seats; said slab means resting on said lower oneof said seats of said ribs, further mechanical fastening means connectedto said slab means at each end thereof for permanently attaching saidslab means to said vertical column means at one end thereof and to saidcorridor means at the other end thereof, whereby said slab means formsthe ceiling of one of said plurality of living compartments and thefloor of another of said plurality of living compartments of saidmultistory building, and said vertical column means forms one outsidewall of said one of said plurality of living compartments and saidcorridor means forms the opposite wall of said one of said plurality ofliving compartments.
 2. A multistory building as in Claim 1 wherein saidvertical column means comprises a plurality of column sections, eachsaid column section being of integrally cast one piece constructioncomprising two substantially vertical columns, each said column beingsubstantially parallel to and spaced a distance from one another,connection means at each end of said vertical columns, a beam extendingbetween said vertical columns and intersecting therewith atsubstantially the respective midpoints thereof, and said beam includingmeans for supporting and securing said slab means.
 3. A multistorybuilding as recited in claim 1 in which said slab means has a mainrectangular area and perpendicularly extending ribs integrally andlongitudinally connected along each edge thereof, each of said ribsbeing in registration with a corresponding one of said vertical ribsintegral with said depending sidewalls.
 4. A multistory building asrecited in claim 1 in which said slabs have a plurality ofperpendicularly extending parallel spaced ribs longitudinally positionedfor alignment with corresponding ribs of said vertically dependingsidewalls of said corridor means.